Claims
- 1. A copper infiltrated iron-phosphorous powder metal article, the article having a composition comprising:
an iron-phosphorous metal powder wherein the iron-phosphorous powder metal is compacted to a matrix, wherein the matrix has a density in the range of 6.0 to 7.2 g/cc; copper in the range of 1.96 wt % to 23.08 wt %, of weight of the article wherein the copper is infiltrated into the matrix; and wherein the article after copper infiltration has a final density in the range of 6.1 to 8.1 g/cc; and wherein an effective amount of phosphorous is present in the iron-phosphorous powder metal to facilitate the infiltration of the copper into the matrix.
- 2. The article of claim 1, wherein the matrix has a density range of 6.5 g/cc to 7.0 g/cc.
- 3. The article of claim 1, wherein the effective amount of phosphorous in the iron phosphorous metal powder is in the range of 0.01 wt % to 1.2 wt % by weight of the iron-phosphorous powder metal.
- 4. The article of claim 1, wherein the amount of phosphorous in the article after copper infiltration is in the range of 0.010 wt % to 1.000 wt % by weight of the article.
- 5. The article of claim 1, wherein the amount of copper in the article after copper infiltration is in the range of 7.4 wt % to 13.04 wt % by weight of the article.
- 6. The article of claim 1, wherein the copper in contact with the matrix before copper infiltration is in the range of 2.0 wt % to 30.0 wt % by weight of the matrix.
- 7. The article of claim 1, wherein the copper is infiltrated during sintering of the matrix.
- 8. The article of claim 1, wherein the copper is infiltrated after sintering of the matrix.
- 9. The article of claim 1, wherein the article has an elongation in the range of 4.0% to 30.0%.
- 10. The article of claim 1, wherein the article has a tensile strength in the range of 310 MPa to 690 MPa.
- 11. The article of claim 1, wherein the article has an impact strength in the range of 20 N-m unnotched Charpy to 203 N-m notched Charpy.
- 12. The article of claim 1, wherein the article has a modulus in the range of 138 GPa to 207 GPa.
- 13. The article of claim 1, wherein the article has yield strength in the range of 220 MPa to 655 MPa.
- 14. A powder metal structure, the structure comprising:
a copper infiltrated iron phosphorous powder metal composite having a composition of:
an iron-phosphorous metal powder having phosphorous in the range of 0.01 wt % to 1.2 wt %, not more than 0.50 wt % of carbon, and balance substantially iron by weight of the iron-phosphorous metal powder; wherein the iron-phosphorous metal powder is compacted to a matrix, wherein the matrix has a density in the range of 6.0 to 7.3 g/cc; copper in the range of 2.0 wt % to 30.0% wt % of the matrix wherein the copper is placed in contact with the matrix and infiltrated into the matrix; wherein the amount of phosphorus in the structure after copper is infiltrated into the matrix in the range of 0.010 wt % to 1.000 wt % of weight of the structure; wherein the amount of copper after copper is infiltrated into the matrix is in the range of 1.96 wt % to 23.08 wt % of weight of the structure; wherein the structure has a density in the range of 6.1 to 8.1 g/cc.
- 15. The structure of claim 14, wherein the matrix has a density 6.5 g/cc to 7.0 g/cc.
- 16. The structure of claim 14, wherein the amount of copper after copper is infiltrated into the matrix is in the range of 7.4 wt % to 13.04 wt % by weight of the structure.
- 17. The structure of claim 14, wherein the copper is infiltrated during sintering of the matrix.
- 18. The structure of claim 14, wherein the copper is infiltrated after sintering of the matrix.
- 19. The structure of claim 14, wherein the structure has an elongation in the range of 4.0% to 30.0%.
- 20. The structure of claim 14, wherein the structure has a tensile strength in the range of 310 MPa to 690 MPa.
- 21. The structure of claim 14, wherein the structure has an impact strength in the range of 20 N-m unnotched Charpy to 203 N-m notched Charpy.
- 22. The structure of claim 14, wherein the structure has a modulus in the range of 138 GPa to 207 GPa.
- 23. The structure of claim 14, wherein the structure has yield strength in the range of 220 MPa to 655 MPa.
- 24. A process for forming copper infiltrated iron-phosphorous powder metal structural member the structural member having a predetermined shape, comprising the steps of:
blending a phosphorous powder with an iron based metal powder to form a iron-phosphorous powder metal, the phosphorous powder being present in the range of 0.01% to 1.2% by weight of the weight of the iron-phosphorous powder metal; compacting the iron-phosphorous powder metal into a perform; infiltrating copper into the preform, the copper after infiltration is present in an amount in the range of 1.96 wt % to 23.08 wt % by weight of the structure; and wherein the structural member after copper infiltration has a density in an range of 6.1 g/cc to 8.1 g/cc.
- 25. The process of claim 24, further comprising the step of simultaneously sintering the preform during the step of infiltrating copper into the preform.
- 26. The process of claim 24, further comprising the step of sintering the preform before the step of infiltrating copper into the preform.
- 27. The process of claim 24, wherein the preform has a density in the range of 6.0 g/cc to 7.3 g/cc.
- 28. The process of claim 24, wherein the amount of phosphorous after infiltrating copper is in the range of 0.01 wt % to 1.000 wt % by weight of the structural member.
- 29. The process of claim 24, wherein the amount of copper after infiltrating copper is in the range of 7.4 wt % to 13.04 wt % by weight of the structural member.
- 30. The process of claim 24, wherein the amount of copper before infiltrating copper is in the range of 2.0 wt % to 30.0 wt % of the weight of the preform.
- 31. The process of claim 24, wherein the structural member has an elongation in the range of 4.0% to 30.0%.
- 32. The process of claim 24, wherein the structural member has a tensile strength in the range of 310 MPa to 690 MPa.
- 33. The process of claim 24, wherein the structural member has an impact strength in the range of 20 N-m unnotched Charpy to 203 N-m notched Charpy.
- 34. The process of claim 24, wherein the structural member has a modulus in the range of 138 GPa to 207 GPa.
- 35. The process of claim 24, wherein the structural member has yield strength in the range of 220 MPa to 655 MPa.
RELATED APPLICATIONS
[0001] This application is claiming priority from. U.S. provisional patent application Serial No. 60/203,215 filed on May 11, 2000.
Provisional Applications (1)
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Number |
Date |
Country |
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60203215 |
May 2000 |
US |